Packaging bag for insertion into a publication

Abstract

 A publication comprising a plurality of pages (141, 147) having parallel opposing top (142) and bottom (144) edges connected by a perpendicular spinal portion (143). The pages are bound together at the spinal portion (143) by binding means; and a packaging bag (120) is bound to the spinal portion. The bag has at least one sealed envelope (129) containing at least one insert and the envelope (129) has overlaying front and back wall portions with at least one top (123) or bottom edges having a trim segment (130), and the spinal edge having an adjacent or coextensive fastening area (131) whereby the bag (120) is bound to the spinal portion (143) of the bound pages (141, 147).

Description

Cross-Reference to Related Application

[0001] This application is a continuation-in-part of U.S. application Serial No.: 07/422,094, filed October 16, 1989, rich application is hereby incorporated by reference.

Background of the Invention

[0002] The present invention relates generally to packages and packaging bags for insertion into publications, processes for making such bags, and publications containing packaging bags. More particularly, the present invention relates to packaging bags for insertion into publications having multiple pages, particularly wherein, in the publication's final form, folded pages or collated pages are fastened together by means such as saddle stitching, side stitching or are perfect bound.

[0003] A variety of different packages for conveying printed matter and/or product samples are known in the art. In one such package multiple objects such as printed items like brochures or reader service cards are enclosed together inside a skin or envelope, with the intended recipient's name and address applied to the outside. One such package or envelope may be made by folding a single, elongate sheet of material around the objects to be included so that the edges of the sheet approximate each other along the sheet's length. A seal is then formed between the edges by any or all of heat, pressure and/or adhesive, to obtain an elongate tube containing multiple, identical units of printed matter, product samples and/or some other object. The tube is sealed and severed between each of these units so that individual packages or envelopes are obtained, with each package or envelope containing a single unit of included material. The intended recipient's address may be preprinted on the inside or outside of the sheet or "wrapper", or on an insert inside the package so that the intended recipient's name and address are visible through a transparent portion of the wrapper. Alternatively, this information may be applied to the individual packages or envelopes after formation of the package or envelope is complete.

[0004] In the past these packages have been used extensively for direct mailing of product samples and product literature, such as "reader service" or response cards, to potential customers. However, these packages have not previously been used as inserts for publications, such as newspapers, catalogs and magazines, perhaps due to the difficulties presented if one were to attempt to secure such a package between a publication's pages.

[0005] One of the most common items used for insertion into publications is a card which is blown between the pages of a publication, either during or after the publication's assembly. However, although this type of insert has several advantages, blown-in cards have the disadvantage of not being secured in the publication, so that they readily fall out and become separated from the publication before it reaches its intended destination. Further, blown-in inserts rely on the force applied by the publication's pages for the insert to remain in place, and hence are inherently unsuitable for conveying materials such as packages of multiple cards or product samples which may be too heavy or bulky for the publication's pages to effectively retain in position.

[0006] Another insert, which may be more securely placed in a publication, is disclosed by U.S. Patent No. 4,509,759. U.S. 4,509,759 discloses a game card for insertion between the pages of a folded publication, therein the game card is printed on a larger portion of a card which is dimensioned such that a smaller portion of the card extends across the fold to the pages opposite those that the game card portion is situated between. Similar inserts, which may be used to convey product samples by laminating the samples to the larger portion of the card, are disclosed by U.S. Patent No. 3,275,316. A similar card, which may have printed advertising thereon and may be folded to provide a return envelope, is disclosed by U.S. Patent 4,011,985.

[0007] A package for conveying soap powder samples is disclosed by U.S. Patent No. 4,433,783. This package is formed by sealing rectangular front and back panels together, with several ounces of soap powder spread in between. Additional seals are provided part of the way across the package to discourage the soap powder from shifting position substantially within the package, while permitting the passage of air from one portion of the package to another. Although this patent indicates such packages may be used as inserts for magazines or newspapers, no means of insertion into publications or means of securing such an insert within a publication is disclosed.

[0008] Also, U.S. Patents Nos. 3,369,732 and 4,795,193 disclose provision of return envelopes in bound publications such as magazines or booklets. These unsealed envelopes are designed to be removed from the publication and used to send a reply through the mail.

[0009] A continuous series of envelopes with detachable edge strips for feeding the envelopes through high speed processing equipment such as printers is disclosed in U.S. Patent 3,608,816. These envelopes may contain printed inserts e.g. useful for example in banking operations to send statements to depositors.

[0010] It is an object of the invention to provide a publication containing a packaging bag having a trim segment and containing at least one insert in a sealed envelope.

[0011] It is an object of the invention to provide a folded publication having a packaging bag containing a plurality of envelopes with at least one on each side of the fold wherein the bag has a pick-up lip located distally from the fold.

[0012] It is an object of the present invention to provide a packaging bag containing inserts such as printed matter and/or product samples, which bag is adapted for binding into a publication.

[0013] It is also an object of the present invention to provide a packaging bag which is suitable for insertion into a publication which is folded in its final form.

[0014] It is an additional object of the invention to provide a packaging bag which may be readily secured within a folded publication wherein the pages are fastened together by saddle stitching.

[0015] It is a further object of the invention to provide a process for making a packaging bag which is particularly adapted for insertion into a publication which is folded in its final form.

[0016] It is yet a further object of the invention to provide a packaging bag which is suitable for insertion into a perfect bound publication.

[0017] It is another object of the invention to provide an insert-­containing packaging bag secured to a perfect bound or saddle stitch bound publication.

[0018] It is yet another object of the invention to provide a package having a trim segment on one or more edges of said package for alignment and/or trimming with a publication during collating and binding.

[0019] It is yet another object of the invention to provide a folded or foldable package having a sealed envelope or envelopes on either side of the fold whereby one side of the package from the fold is longer than the other, thus providing a pick-up lip for use in a collating operation.

[0020] It is not necessary that each of the above objects be acheived in all embodiments of the invention. These and additional and alternative objectives and advantages of the present invention will be readily apparent to those skilled in the art from the present invention as below shown in the drawings, and as described and claimed.

Summary of the Invention

[0021] The present invention is directed to a publication comprising a plurality of pages, wherein the pages have parallel opposing top and bottom edges connected by a spinal portion which extends perpendicular to the top and bottom edges and the pages are bound together at the spinal portion by binding means. This publication contains a packaging bag bound to the spinal portion, and this bag comprises at least one sealed envelope containing at least one insert therein. The bag's envelope comprises overlaying front and back-all portions, each of these wall portions having opposing top and bottom edges connected by opposing spinal and side edges with at least one of the top and bottom edges having a trim segment, and the spinal edge having an adjacent or coextensive fastening area whereby the bag is bound to the spinal portion of the aforementioned plurality of bound pages.

[0022] In one embodiment the present invention is directed to a packaging bag particularly adapted for insertion into a publication which is folded in its final form. This packaging bag comprises a plurality of sealed envelopes containing one or more inserts. These envelopes are attached to each other along at least one margin of the envelopes. At least two of the envelopes are separated by a fastening area such that at least one of the inserts in one of the envelopes is different from the inserts in an adjacent envelope.

[0023] Another embodiment of the present invention also is directed to a packaging bag which consists essentially of two sealed, insert-containing envelopes attached to each other along one margin of the envelopes and being separated from each other by a fastening area and which optionally has at least one trim segment and/or pick-up lip.

[0024] Another embodiment of the present invention includes a packaging bag which comprises a plurality of sealed envelopes which are attached to each other along at least one margin of said envelopes, and a fastening area. The fastening area is positioned between at least two of the envelopes and includes means for making the packaging bag bend preferentially at the fastening area.

[0025] Optionally, the portion of the packaging bag on one side of the fastening area is slightly larger or longer than the portion on the other side of the fastening area.

[0026] It is preferred in multi-envelope embodiments of the invention that each envelope be separated by the adjacent envelope or envelopes by at least one seal, although at least two substantially parallel seals are more preferred. It is also preferred that the seal extend across the width of the envelope.

[0027] It is further preferred that the optional means for making the packaging bag bend preferentially at the spinal edge or at the fastening area include a score and/or a plurality of perforations in the fastening area. This score or these perforations preferably are located between two substantially parallel seals.

[0028] The present invention is also directed to a process for making a packaging bag which is particularly adapted for insertion into a publication which is folded in its final form. This process comprises the steps of placing insert material inside a tube; sealing said tube widthwise periodically along its length to form a plurality of compartments which are separated from each other by at least one seal; and cutting said tube widthwise periodically along its length so that said tube has two to four compartments between adjacent cuts and optionally folding the bag so that the opposing portions of the bag which extend from the fold are of uneven length to facilitate handling e.g. collation in a saddle stitch binding operation.

[0029] Preferably the tube is formed by the steps of wrapping a continuous web of sheet stock around a form and said insert material so that two opposite edges of said stock approximate each other and said insert material is enclosed therein; and sealing said opposite edges together to form said tube. Also, the edges may be folded in offset fashion. Alternatively, a seamless, tubular film may be formed by known means in the first instance, thereby reducing the number of seals for each compartment from three to two.

[0030] The seals may be formed by the application of pressure to the tube with or without an adhesive such as glue, and more preferably by the application of both heat and pressure with or without an adhesive such as glue.

[0031] Either tubular or sheet stock may be employed, having monolayer or multilayer construction. Suitable stock includes paper, cellophane, metal foils and thermoplastic films including those made from polyesters, homopolymers and copolymers of olefins, such as polyethylene and polypropylene, linear low density polyethylene and very low density polyethylene. Also, films made from biodegradable plastics including cellulosic and starch-derived materials may be suitably employed. The stock may be single layer or multilayer stock formed by well known lamination processes or coextrusion means. The stock may be coated with various agents to improve printability, sealability, or to control static electricity or other parameters. The stock may also be metallized. Many such films are commercially available and All known in the art. Examples of preferred stock include paper, polyethylene, polypropylene and a laminate of metallized polyester and polyethylene.

[0032] The present invention additionally is directed to a publication containing a packaging bag, comprising a plurality of pages folded and collated to form a multi-page publication having a central fold, and a packaging bag which includes a plurality of sealed envelopes containing one or more inserts, the envelopes being attached to each other along at least one margin, such that at least two envelopes are separated by a fastening area. The packaging bag is inserted between pages of the publication such that the fastening area overlaps the central fold, and at least two of the envelopes are on opposite sides of the fold.

[0033] This publication preferably is stapled periodically along the fold, with staples preferably being placed on each side of the packaging bag fastening area, and more preferably at least one staple being stapled through the fold and the fastening area.

[0034] The position of the packaging bag may "float" e.g. between two staples or be located anywhere from the top to the bottom of the publication, but preferably will be fastened with an edge of the bag coextensive with the top or bottom edge of the publication.

Brief Description of the Drawings

[0035] 

Fig. 1 is a front view of the preferred embodiment of the packaging bag of the invention.

Fig. 2 is a back view of the embodiment of Fig. 1.

Fig. 3 is a bottom view of the embodiment of Fig. 1.

Fig. 4 is a bottom view of the embodiment of Fig. 1.

Fig. 5 is a cross-sectional view of the embodiment of Fig. 1, taken along dotted line 5-5 in Fig. 1.

Fig. 6 is a front view of an alternative embodiment of the packaging bag of the invention.

Fig. 7 is a front view of an alternative embodiment of the packaging bag of the invention.

Fig. 8 is a front plan view of an embodiment of the publication of the invention, showing the preferred embodiment of the packaging bag of the invention inserted between the pages.

Fig. 9 is an exploded vied of a machine useful in the preferred embodiment of the process of the invention.

Fig. 10 is a schematic view of a process of making a bag according to the present invention.

Fig. 11 is a front view of an embodiment of a packaging bag according to the invention.

Fig. 12 is a front view of a publication containing a packaging bag according to the invention.

Fig. 13 is a top view of the embodiment of Fig. 12.

Fig. 14 is a top view of the embodiment of Fig. 13 after trimming, binding and covering.

Detailed Description of the Invention

[0036] Publication as that term is used herein means a printed work on paper or a synthetic paper and includes magazines, newspapers, brochures, catalogs, booklets, periodicals, books and the like, all of which contain a plurality of pages. A web or roll of paper may be printed on either or both sides and subsequently cut into sheets, or cut sheets may be so printed. Thus, a single sheet of paper may have printing on both faces or sides to form a single leaf having two pages in a publication. Alternatively, a single sheet may have printing on one or both faces so that the sheet may be folded in half to produce a folded sheet having two leaves and four pages. Similarly, a single sheet may be printed such that it may be folded multiple times to produce a publication of multiple leaves and many pages and this may be termed a signature. One or more signatures may be bound along or adjacent to one fold, termed a spine, and subjected to a cutting or trimming operation to form leaves which are connected at a coextensive spinal edge or fastening area and yet which are separable at the side opposite the spine and separable as well at the top and bottom so that the leaves may be turned to view each page. The leaves or pages may be bound together at the spinal portion or at an adjacent fastening area by binding means including mechanical or chemical binding means such as sewing, stapling or use of an adhesive.

[0037] A significant number of publications, such as many newspapers, catalogs and magazines, are produced by printing at least two pages of indicia such as type, photographs and/or drawings, separated by a blank strip (gutter), on the front, back, or both front and back faces of a sheet or a web which is later cut into sheets. The printed sheets contain facing pages which may then be collated with other similarly printed pages, and the sheets folded along the blank strip to create a multiple-paged publication wherein each of the above-described sheets forms two leaves. In some publications, such as many magazines and catalogs, but usually not newspapers, the sheets are fastened together in the area of the fold, such as by staples (currently referred to in the art as "saddle stitching") or some other similar device, to make the publication more durable during distribution and reading. Some publications, such as newspapers, may subsequently be folded one or more additional times to facilitate storage, mailing or other modes of distribution. For the purposes of the present application the "final form" of a publication is that form in which a publication ordinarily is used by a consumer.

[0038] Fundamental to the present invention is provision of a packaging bag having at least one sealed envelope containing at least one insert, which bag is adapted for binding into a publication.

[0039] In one embodiment of the invention, a package comprises a sealed envelope containing at least one insert. This envelope has a front wall and a back wall with connected sides. At least two sides of the envelope have a trim segment with at least one of these trim segments extending perpendicular to the other trim segment. Each trim segment is of sufficient width for removal by a trimming operation without opening the envelope. This width is typically at least 1/16 inch, preferably at least 1/8 inch, and may be at least 1/4 inch. Beneficially, trim segments will range in width from about 1/16 inch to about 1 inch with a preferred range of between about 1/8 inch to about 1/4 inch. Larger trim widths may be employed, but generally offer no material advantage and contribute to waste. Too small of a trim width may cause an envelope to be cut open during trimming, thereby undesirably and prematurely releasing its contents. Also, if the trimming operation is set to trim too little off the edges of the publication's pages, then the resultant trimmed publication will have a sloppy appearance with uneven page edges. Therefore the trim segments should be of sufficient width to fulfill their purpose, which is to allow collation of the package or packaging bag with a plurality of pages which will subsequently be bound and trimmed to form a publication having a neat appearance with even edges. The trim segments will generally have straight edges thereby allowing the trim segment edges to be utilized to align the package or bag with at least one edge coextensive with the spinal or backbone portion of the publication and preferably also having a bag edge coextensive with either the top or bottom edges of the publication. For example, during collation the packaging bag may be jogged to the top or bottom of a plurality of pages, or float to any position in between and then be bound in place and trimmed.

[0040] In another embodiment of the invention, a package comprising a thin walled bag having a top edge and opposing bottom edge connected by opposing first and second side edges is provided. This bag has a fastening area with an optional fold (or fold line) therein which extends from the top edge to the bottom edge of the bag. Also this bag has on each side of the fastening area at least one sealed envelope containing at least one insert, and the distance from the fold (or fold line) to the first side edge of the bag is different from the distance from the fold (or fold line) to the second side edge of said bag.

[0041] The difference in distance between the fold (or fold line) and the respective opposing first and second side edges is beneficially at least about 1/4 inch, probably at least about 3/8 inch and most preferably at least about 1/2 inch. This difference provides an offset portion, termed a "pick-up lip", which may be used to manipulate the bag during collation with a publication. Optionally the bag is folded and a plurality of bags provided to a bindery in a folded condition. The bindery may easily use known equipment to handle and manipulate the folded bags in a manner similar to that used for folded pages in a bindery operation. Preferably, the bag is folded along a fold line which may be formed e.g. by a score and/or a series of perforations. In a preferred version of the embodiment at least one of the top, bottom, and side edges of the bag will further comprise a trim segment.

[0042] The invention is applicable to publications having various types of binding, and various embodiments may have particular advantages for certain types of binding operations. In general, there are five operations or steps which may be utilized in the production of a bound publication, viz scoring, folding, collating, stitching, and trimming. Publications may be formed using some or all of the above operations. In a typical, well-­known operation for the production of a publication, such as a magazine, the following operations may take place. A web of paper is printed on both sides, then cut into sheets with scoring occurring simultaneously with, or subsequent to, cutting. A "score" as the term is used herein is defined as a crease in a web or sheet which is made to facilitate folding. Scores may be of varying widths. Folding may also be facilitated by a series of perforations. Scoring may be performed using a scoring rule which is raised from the surface of a plate or cylinder to impress or indent a crease into paper as the paper contacts the plate or cylinder.

[0043] The scored paper may be folded e.g. using a buckle type folding machine in which a sheet is fed into a fold-plate of adjustable length which has a stop. The sheet is forced into the stop causing the sheet to buckle about the score line and then carried between rollers which fold the sheet. The folding operation may include both parallel and right angle folds. Folding machines may have attachments for scoring, perforating, slitting, trimming and/or pasting. It is known to fold a sheet into a signature of as many as 64 pages. Folds may also be made without scoring or perforating.

[0044] After folding, the folded sheets (signatures) are collated to collect together in proper sequence the intended pages of the publication.

[0045] The collated signatures (or pages of a single signature or folded sheet) may then be bound together in a stitching operation. The term "stitching" arises from an historical method of binding where the leaves or sheets of a publication were sea together. Sewn binding may be used in the present invention, however "stitching" has also come to refer to other binding means such as stapling with one or more metal staples.

[0046] Two types of such stitching are the "saddle stitch" and the "side stitch". In saddle stitching the fold, or at least one portion of the fold, of one or more folded sheets or signatures which will form the bound or spinal portion of the publication rides atop a saddle with opposing leaves hanging down on either side of the saddle. The saddle is then positioned under a stitching head which forces at least one and preferably two or more staples through the spinal or backbone portion at the fold to bind the leaves together at the fold. This is a common, simple and inexpensive form of binding.

[0047] In side stitching the folded and collated pages are placed under a stitching head where at least one, and preferably at least two staples are inserted through a fastening area adjacent to the fold or spinal portion. In a side stitched publication, staples are typically inserted about 1/4 inch from the backbone or spinal edge and enter first through the leaves on one side of the fold and then exit through the leaves on the other side of the fold. Saddle stitched publications are generally easier to open and will more easily lie open flat than side stitched publications. However, side stitching is generally used for publications too thick for suitable saddle stitching.

[0048] Publications such as magazines may also be "perfect bound". Perfect binding is an inexpensive way to bind together pages or leaves usually of a relatively thick publication. Perfect binding may be thought of as a variation in side stitching in which, after collation of the signatures or pages, the collated leaves are held together while a portion of the backbone or spinal portion is ground off to produce a rough spinal edge with evenly placed (coextensive) spinal page edges to which a flexible adhesive is applied. A cover is then glued to the spine over the bound publication. Known in the art are suitable adhesives which maintain sufficient flexibility, resilience and strength for the expected useful life of the publication. A spinal portion of a plurality of pages may extend along a backbone edge of a plurality of folded or unfolded collated sheets or pages and this spinal portion may be utilized as the fastening area to bind together the sheets or pages into a bound publication. Both perfect binding and side stitch binding may be employed to bind together a plurality of unfolded sheets or leaves. In binding together separate unconnected leaves or pages which have not been folded, a trimming operation, while unnecessary to open up the top, bottom and/or side edges to allow the pages to be freely turned about an axis coextensive with the bound spine, may be used to produce even coextensive page edges producing a publication with a neat appearance and smooth uniform edges. Another type of suitable binding is a mechanical binding using e.g. a wire spiral or plastic coils.

[0049] After binding, the publication is usually trimmed on the top, bottom and at the side edge opposite the bound spine. The top, bottom and side edges may be trimmed serially or simultaneously using apparatus well known in the art.

[0050] In another embodiment of the invention a publication is provided which contains a packaging bag comprising (a) a plurality of pages folded and collated to form a multi-page publication having a central fold, and (b) a packaging bag which includes a plurality of sealed envelopes containing one or more inserts and being attached to each other along at least one margin of the envelopes with at least two of the envelopes being separated by a fastening area. The packaging bag is inserted between the pages of the publication such that the fastening area overlaps the publication's central fold with at least two of the bag's envelopes being on opposite sides of the fold i.e. one envelope is on one side of the fold and another envelope is on the opposite side of the fold.

[0051] Preferably the packaging bag is secured between the pages of the publication by fastening means which may be chemical means such as an adhesive or mechanical means such as crimping or use of one or more staples. The point of attachment of the fastening means will be in the fastening area and preferably at the central fold. Preferably, at least one staple is stapled through the fastening area and the central fold to bind the bag and publication pages together.

[0052] In another embodiment of the invention a publication is provided which comprises a plurality of pages, wherein these pages have parallel opposing top and bottom edges connected by a spinal portion which extends perpendicular to the top and bottom edges. These pages are bound together at the spinal portion by binding means and a packaging bag is also bound to the spinal portion. This bag comprises at least one sealed envelope containing at least one insert and this envelope comprises overlaying front and back wall portions with each of these wall portions having opposing top and bottom edges connected by opposing spinal and side edges. At least one of the top and bottom edges of the bag has a trim segment, and the spinal edge of the bag has an adjacent or coextensive fastening area whereby the bag is bound to the spinal portion of the plurality of bound pages.

[0053] It should be understood that features disclosed below with respect to one embodiment may be found in other different embodiments of the invention and that such descriptions e.g. with respect to materials, shapes, sizes, number, insert types and formation, binding types and means, etc. unless specifically excluded from a particular embodiment may be utilized. It should also be realized that one of ordinary skill in the art may combine the various disclosed features in various combinations in view of the present disclosure and that such combinations are contemplated by the present invention.

[0054] Referring now to Fig. 1, the present invention in one embodiment is directed to a packaging bag 10 which is particularly suited for insertion into a publication which is folded in its final form. This packaging bag may have printed or embossed indicia 11 thereon. The bag 10 comprises a plurality of sealed envelopes, such as left envelope 12(a) and right envelope 12(b) having front surfaces 13(a) and 13(b), respectively. A fastening area is positioned between two envelopes, such as fastening area 14 positioned between envelopes 12(a) and 12(b). Fastening area 14 preferably contains a score and/or perforations 15, and is located between inner seals 16(a) and 16(b). The fastening area 14 and score and/or perforations 15 will beneficially extend in continuous fashion from packaging bag top edge 17 to bottom edge 18 to provide an area adapted for positioning and securing the bag within the folded area of a publication, and to provide means for easy separation and removal of the envelopes 12(a) and 12(b) by a reader.

[0055] Each of the envelopes 12(a),(b) is attached to another envelope along at least one margin, such as margins 19(a), (b) in Fig. 1. The envelopes may be attached either directly (such as envelopes 46(a) and (b) in Fig. 7 which share horizontal inner seal 47) or by being affixed to some intermediate means, as shown in Fig. 1 with envelopes 12(a), (b) being attached to each other through seals 16(a),(b) and fastening area 14.

[0056] Although the envelopes may be separately formed and subsequently fastened together by conventional chemical or mechanical means using e.g. adhesives, stitching or staples, it is preferred that both envelopes be formed from unified, integral pieces of material, such as a tube or two overlapping pieces of stock or a single folded sheet of stock, so that no separate attachment means is required to connect adjacent envelopes.

[0057] Each envelope is adapted to hold one or more inserts (not shown). The packaging bag 10 is preferably formed of a film or material which is tubular in shape. Left envelope 12(a) is formed from this tube with top surface 13(a) having a top edge 17 connecting left edge 20 of left margin 21 to bottom edge 18 which in turn is connected to top edge 17 by right margin 19(a). The tube forms an envelope adapted for holding inserts by having substantially parallel, spaced apart left inner seal 16(a) and left outer seal 22(a). Seal 16(a) is adjacent to right margin 19(a) and extends from top edge 17 to bottom edge 18. Seal 22(a) is adjacent left margin 21 and also extends from top edge 17 to bottom edge 18 but is spaced apart from seal 16(a) to form envelope 12(a) for holding inserts.

[0058] In various embodiments of the present invention seals such as seals 16(a) and 22(a) may be continuous or intermittent, and these seals may be narrow or wide or of varying width. The seals may be formed by use of mechanical fasteners such as staples, or by an adhesive, or by pressing together a self-­adhering inner surface of the envelope, or by fusion bonding the envelope's inner surface to itself or an outer surface by applying heat and pressure. It will be recognized that the sealing parameters need only be sufficient to retain the inserts within the envelope until removal is desired, such as by a reader or customer. Similarly opposing adjacent envelope 12(b) is formed by right inner seal 16(b) and right outer seal 22(b) connecting top edge 17 to bottom edge 18.

[0059] At least two envelopes, separated by a fastening area, are required by this foldable embodiment of the invention.

[0060] It is further preferred that the weight of the portion of the packaging bag, including inserts, on one side of the fastening area, such as in Fig. 1 envelope 12(a) to the left of fastening area 14, be substantially the same as the weight of the portion, including inserts, on the other side of the fastening area, such as 12(b) to the right of fastening area 14, in order to facilitate handling and proper alignment of the packaging bag when the packaging bag is incorporated into a publication, such as during collating. However, consistent with the preferred embodiment, some slight deviation, preferably about 10% or less, based on the total weight of the packaging bag, may be present. Variations in weight greater than 10% are also contemplated by the invention.

[0061] Referring to Fig. 2, a back view of the embodiment of Fig. 1 is presented where the packaging bag 10 is formed according to the preferred embodiment of the process of the invention such that the bag is formed from a single piece of sheet material. The sheet material is folded at top edge 17 and bottom edge 18 to produce a tube or enclosure, having a continuous periphery, by means of a longitudinal or "fin" seal 24 which connects opposing side portions of the sheet. Fin seal 24 typically runs the length of the packaging bag. Although this seal may be positioned at the top, bottom, front or back of 'the bag or at any place in between, consistent with the invention, in an embodiment where the bag is positioned away from but between the top and bottom edges of the publication it is preferred that the fin seal be on the back of the bag, as shown at 24 in Fig. 2, to reduce stress on the seal by packaged inserts having edges positioned at the top or bottom of the bag, and to allow an aesthetically pleasing display of information on the front.

[0062] In a most preferred embodiment the longitudinal seal will be either at the top or bottom of the bag and contain a trim segment. When the seal is at the top the bag will preferably be bound to the publication with its top edge coextensive with the top edges of the collated pages of the publication. Similarly, when the seal is at the bottom of the bag, the bag will be jogged to the bottom position during a collation operation and bound there with its bottom edge adjacent to and coextensive with the bottom edges of the publication's collated pages. In this manner the bag may be trimmed along with the publication's pages without opening the sealed envelopes.

[0063] Envelopes 12(a),(b) are formed by connecting back sheet portions 25(a) and (b) to the front sheet portion (see 13(a),(b) in Fig. 1) by sealing. Seals 16(a) and 22(a) connect top edge 17 to bottom edge 18 to form envelope 12(a) and seals 16(b) and 22(b) similarly connect top edge 17 and bottom edge 18 to form opposing envelope 12(b) which adjoins envelope 12(a) along fastening area 14 and a score and/or perforations 15 extending from top edge 17 to bottom edge 18. Unlike seals 16(a),(b) and 22(a),(b), fin seal 24 does not seal back sheet portions 25(a) and 25(b) to the front sheet portion 13 (see Fig. 1). Instead, fin seal 24 connects back sheet portion 25(a) to back sheet portion 25(b) by aligning edges 26 of each portion 25(a) and 25(b) and sealing the inner surfaces of the sheet material together. Either or both of the back sheet portions 25 (a) and 25(b) may have indicia 11 printed thereon.

[0064] In contrast to some envelopes known in the art which are empty and unsealed when incorporated into a publication and are intended to be torn out by the consumer and have the consumer insert material therein, all embodiments of the present invention contemplate that the packaging bag will be sealed to the outside so that an insert material, and preferably a plurality of inserts, is already contained within the bag when the bag is inserted in a publication, such as inserts 27 in envelope 12(b) as shown in Fig. 5. The particular type of insert material enclosed within the bag is not critical to the invention, but may be pre-packaged product samples such as, for example, cleaning supplies, agricultural chemicals, computer disks, cologne, detergent, cosmetics or personal hygiene or personal care products, or may be written or printed material such as product literature, brochures, reader service return post cards, return envelopes, photographs, or other pictorial materials or any combination thereof. Further, although an envelope may contain a single insert, such as a brochure or vial, a plurality of inserts may be enclosed within the same envelope, such as a product sample and related product literature or a stack of return post cards to use in requesting information regarding different products. Preferably at least one of the inserts in one of the envelopes is different from the inserts in an adjacent envelope. In multi-envelope embodiments it is preferred that all of the inserts in the envelopes on one side of the fastening area be different from the inserts in the envelopes on the other side of the fastening area. It is further preferred that all of the inserts in each of the envelopes be different from the inserts in the adjacent envelope or envelopes, so that the packaging bag may be used to convey a wider variety of inserts. By different is meant a difference e.g. in information conveyed or in product ingredients rather than insert type, although different insert types are also contemplated. For example, printed cards may be in adjacent envelopes but the cards may bear differing indicia thereby making them different inserts. Similarly packets of product samples such barbecue sauce could be in adjacent envelopes yet be different by virtue of one packet containing extra or different spices (hot versus mild).

[0065] A fundamental aspect of the present invention is that the packaging bag is sealed before insertion of the bag into a publication, so that materials, for example printed matter and product samples, are already present in the bag envelopes prior to assembly of the publication and therefore can not readily be introduced into the bag once formation of the packaging bag is complete. Thus the present invention permits insertion of filled packaging bags into bound publications such a perfect bound, side stitched or saddle stitched publications whereby the bags may comprise filled envelopes having a thickness up to 1/4 inch or greater and a weight of up to 30 grams or greater. Preferably the bag, including inserts, will have a thickness of at least 1/32 inch, and more preferably 1/16 inch, even more preferably 1/8 inch and most preferably at least 3/16 inch. The thicker the insert-containing bag, the more inserts or the larger the insert one is able to attach to a publication. However, increasing thickness and/or weight may present problems in assembly of the bag-containing publication and/or problems in preventing premature separation of bag envelopes from the attached publication during shipping and/or handling e.g. by height induced tearing along the fastening area. Smaller thicknesses will provide greater publication page contact on opposing sides of a bag envelope while inserted within a publication, which is believed to increase the frictional contact between pages near the bag envelope outer edges thus helping to prevent or reduce twisting motion along the fastening area which may contribute to premature separation.

[0066] It is preferred that in multi-envelope embodiments each of the envelopes be separated from each adjacent envelope by at least one seal so as to discourage or prevent the contents of an envelope from substantially shifting position and from mixing with the contents of another envelope. Referring to Fig. 2, envelope 12(b) may be sealed from envelope 12(a) by means of one or both of inner seals 16(b) and 16(a). Referring to Fig. 7, the contents of envelope 46(a) may be sealed from envelope 46(c) by means of vertical inner seal 54(b) and/or 54(c), and from envelope 46(b) by means of horizontal inner seal 47. In the multi-envelope embodiment which is most preferred, each envelope is separated from each adjacent envelope by at least two (and more preferably only two) substantially parallel seals, such as parallel seals 16(a),(b) separating envelopes 12(a),(b) in Fig. 2. This is especially preferred for opposing envelopes connected by a fastening area 14 which is adapted for attachment to a publication. Inner seals, such as 16(a),(b), which span the entire width of the envelope are preferred.

[0067] Referring now to Fig. 3 which is a bottom view of the embodiment of Fig. 1, packaging bag 10 having opposing edges 20(a) and 20(b) is depicted with envelopes 12(a),(b). The envelopes 12(a), (b) are defined by front surfaces 13(a), (b) which extend around bottom edge 18 to form rear surface 25(b), which in turn is sealed to rear surface 25(a) (see Fig. 2) by fin seal 24, and are further defined by seals 22(a) and 16(a) (for envelope 12(a)) and seals 22(b) and 16(b) (for envelope 12(b)). Seals 16(a) and 16(b) are connected by fastening area 14 which optionally has a score and/or perforations 15 located in the middle thereof at a spinal edge.

[0068] According to one embodiment of the invention, the fastening area 14 is positioned between at least two envelopes, such as between envelopes 12(a),(b) in Fig. 3. In all embodiments of the invention the fastening area may be reinforced in comparison to other parts of the bag, such as by lamination to an additional layer of plastic sheeting, it is contemplated that the inserts will not be contained within the fastening area. Ordinarily, this results in the packaging bag being less thick and less rigid in the fastening area than in the area of the insert-containing envelopes. The fastening area should be sufficiently thin and flexible so that the packaging bag may be readily slipped between the sheets or leaves forming a multi-­paged publication, with the fastening area coextensive with or at least partially overlapping the area which will become the publication's spine or central fold. The packaging bag may have a spinal edge which is common to and coextensive with at least two opposing sealed envelopes which are connected by the bag's spinal edge. This spinal edge of the bag may be coextensive with the bag's fastening area and the bag's fastening area may be common to the opposing envelopes. Alternatively, opposing envelopes may have opposing fastening areas connected by and adjacent to a bag's spinal edge.

[0069] In multi-envelope embodiments having a fastening area separating at least two sealed envelopes, it is further preferred that the fastening area include optional means for making the packaging bag bend or "break" preferentially at the fastening area in contrast to other parts of the packaging bag regardless of the presence or absence of inserts. For example, when the packaging bag is formed from a laminated material, one layer of material may be thinner or missing in the region of the fastening area, so that the bag in the fastening area is thinner and more flexible. Additionally or alternatively, such means may be introduced during or after assembly of the bag, such as by producing a fold line by scoring and/or perforating the bag e.g. at the spinal edge or in the fastening area, such as perforations 15 in Fig. 1. Means such as scoring and/or perforations are preferred, as these may be used to make the fastening area bend or "break" preferentially in a very localized area, thereby defining a spinal edge and permitting a more exact positioning of the packaging bag during insertion of the bag into a publication. Preferably, the bag will be folded and may be provided in a filled and folded condition to a publication bindery for insertion into a publication. The fold will generally form a spinal edge of the packaging bag which may be utilized in a saddle stitch binding operation for collation in a manner similar to the collation of a publication's folded sheets. Also, the spinal edge may be constructed with a trim segment to allow the bag to be collated with sheets in a perfect bound publication with subsequent trimming and binding operations of the collated pages and bag. Optionally, the distance from the common and coextensive spinal edge to the side edge of at least one of at least two opposing envelopes is greater than the distance from the spinal edge to a side edge of the second of the opposing envelopes. In other words the distance from the fold or a fold line (made e.g. by forming a score in the fastening area) to a first side edge of the bag distal from the fold will be different from the distance from the fold to a second opposing side edge of the bag. This difference allows the side edge of the longer bag portion to act as a pick-up lip which may be positioned mechanically e.g. by gripping and/or by suction to facilitate collation in a saddle stitch binding operation. Preferably, this difference in distance will be at least 1/4 inch thereby forming a 1/4 inch wide pick-up lip which extends along the side edge of the packaging bag on the more distally located side edged from the fold or fold line which is located in the fastening area. Preferably, the pick-up lip width is at least 3/8 inch, and more preferably at least 1/2 inch. Illustratively, Fig. 4 shows packaging bag 10 folded along fastening area 14 so that envelope 12(b) is along side envelope 12(a) so that surface 25(b) of envelope 12(a) is next to or touching surface 25(b) of envelope 12(b). Fastening area 14 between seals 16(a) and 16(b) is most severely bent along perforations 15. It is further preferred, in the embodiment wherein at least two of the envelopes are separated by a plurality of substantially parallel seals, that the scoring or perforations be located between (preferably midway) and substantially parallel to the seals, such as perforations 15 between seals 16(a) and 16(b) in Figs. 1 - 4.

[0070] Optionally, the distance along the packaging bag from fold 15 along envelope 12a to side edge 20a is different, e.g. less than the corresponding measurement from fold 15 along envelope 12b to side edge 20b so that a pick-up lip 20c is provided to facilitate binding e.g. in a saddle stitch binding operation.

[0071] Referring now to Fig. 5, a cross-sectional view is presented taken along line 5-5 of Fig. 1 of packaging bag 10. Envelope 12(b) of bag 10 has a generally tubular shape formed by front surface 13(b) which extends at opposing ends 17 and 18 into respective back sheet portions 25(a) and 25(b). A margin area 28(a) and 28(b) of respective back sheet portions 25(a) and 25(b) terminates in aligned edges 26. Margin portions 28(a),(b) are bonded together to form fin seal 24. Envelope 12(b) defines an interior space 29 which contains a plurality of inserts 27.

[0072] Suitable inserts useful with all embodiments of the present invention include printed matter such as cards, brochures, envelopes and/or product samples (with such product samples preferably being pre-packaged) such as seeds, swatches of fabrics or other materials, paint chips, liquid or solid chemicals such as perfume or cosmetics, detergent, computer screen wipes, coupons, sweepstakes tickets, personal hygiene products such as shampoo, deodorant, anti-perspirant, etc. Generally, any food, drug or cosmetic will advantageously be pre-packaged prior to insertion into the packaging bag. This prepackaging has the advantage of allowing a printed insert such as an instruction sheet, patient package insert, survey card, recipe, etc. to accompany the product sample. A further advantage of the pre-packaging is that a product sample manufacturer may supply samples already packaged in conformity to governmental regulations, e.g. for food contact, to a secondary packager who need not be concerned with reactivity between packaging bag materials and the product sample and who may then economically package different inserts simultaneously using a single type of packaging material. Therefore, for example, cough syrup may be pre-packaged in a suitably inert package meeting all applicable governmental regulations for packaging materials in contact with a drug or comestible. Cough syrup, being a liquid (or solid in liquid suspension), will presumably require a packaging material which is either impermeable or acts as a barrier to transfer of the syrup across the packaging material and which is also non-reactive therewith. This pre-packaged syrup may be inserted either alone or with a second insert such as printed patient instructions and/or cautionary information into one envelope while an adjacent envelope contains a different insert which may be totally unrelated such as fabric swatches or printed cards bearing indicia e.g. advertising household services. These envelopes may be made using inexpensive materials such as paper or polypropylene without concern for odor, oxygen or moisture permeability or reactivity with the product sample (in this example cough syrup but the product sample could similarly be perfume or a food product, etc.). In this manner the invention provides for economical packaging (for insertion into a publication) of a wide variety of products having different physical and chemical properties and therefore different packaging requirements.

[0073] Suitable materials for constructing packaging bags and envelopes of the present invention include metal foils such as aluminum foil, cellulosic materials such as paper or cellophane, and thermoplastic films such as polypropylene, polyester, polyethylene or copolymers thereof, or combinations of metal, plastic and/or cellulosic films. It is contemplated that a bag or envelope may comprise one or more layers of the same or different materials. Use of paper may be preferred to facilitate recycling e.g. of the severed trim segments of the bag along with the trimmed edges of a publication's pages or for recycling the entire publication including the bag or bag fastening area.

[0074] Different inserts may be packaged by continuous insertion into packaging bags according to the present invention so that either adjacent envelopes of a single packaging bag contain different inserts, or adjacent packaging bags destined for insertion into a single publication and having a single envelope (or a plurality of envelopes) may be manufactured with the adjoining bags having different inserts. Thus, a publication may be provided with a plurality of unique (non-duplicative) inserts which have been inserted into packaging bags in a continuous packaging operation. These insert-containing bags may be continuously formed, boxed (Optionally in a folded form with opposing envelopes when destined for saddle stitch binderies) and shipped to a bindery for insertion into a publication.

[0075] In certain embodiments more than two envelopes may be included. Referring now to Fig. 6, a front view is depicted of an alternative packaging bag 30 which has a continuous peripheral edge 31 formed by connecting top edge 32 and parallelly displaced bottom edge 33 with spaced apart parallel left edge 34 and right edge 35 to form a rectangular bag 30 having several compartments or envelopes 36(a),(b),(c) and (d) attached together. Envelopes 36(a),(b),(c) and (d) are all formed by sealing a front surface 37 of the bag 30 to a rear surface (not shown) of the bag 30. These seals for each of envelopes 36(a),(b),(c) and (d) extend from the top edge 32 to the bottom edge 33. Envelope 36(a) is defined by seals 38 and 39, envelope 36(b) by seals 39 and 40, envelope 36(c) by seals 41 and 42, and envelope 36(d) by seals 42 and 43. Thus envelopes 36(a),(b),(c) and (d) are attached together in a linear fashion with fastening area 44 between envelopes 36(b) and 36(c).

[0076] More envelopes are shown in the alternative embodiment depicted in Fig. 7 wherein packaging bag 48 has envelopes 46(a),(b),(c) and (d) which are attached together in a matrix fashion Ath fastening area 49 spanning the area between envelopes 46(a) and 46(c), and 46(b) and 46(d), respectively. However, a packaging bag which has only two envelopes, such as 12(a), (b) in Fig. 1, is preferred. Bag 48 of Fig. 7 has a top edge 50 and bottom edge 51 connected by opposing left and right side edges 52 and 53, respectively. Four parallel vertical seals 54(a),(b),(c), and (d) cross horizontal inner seal 47 to defined envelopes 46(a),(b),(c), and (d). Fastening area 49 is bisected by perforations 55.

[0077] Referring again to Fig. 6, it should be clear that the individual envelopes such as 36 (a) and 36 (b) of packaging bag 30 need not be of the same dimensions. It is preferred that the overall width of the portion of the packaging bag on one side of the fastening area 44 such as left portion 45(a) from top edge 32 to bottom edge 33 in Fig. 6 (or 23(a) from top edge 17 to bottom edge 18 in Fig. 1) be of substantially the same width as the corresponding portion on the other side of the fastening area such as right portion 45(b) in Fig. 6 (or 23(b) in Fig. 1). Optionally the length of the packaging bag(s) on one side of a fold line e.g. a score or series of perforations 15 may be sufficiently different from that of the bag(s) on the other side so as to provide a pick-up lip 35a having an edge 35 and extending from top edge 32 to bottom edge 33. The pick-up lip may be used in the binding process to facilitate collation and positioning of the packaging bag in a saddle stitch bound publication such as a magazine. The pick-up lip is generally at least 1/4 inch wide with a length extending from the top edge 32 to the bottom edge 33. The pick-up lip 35a may be lifted or gripped mechanically or by suction to manipulate and position the bag during a binding or collating operation. Packaging bags such as 10 in Fig. 1 and 48 in Fig. 7 wherein the envelopes are all of substantially the same dimensions are preferred.

[0078] The present invention is also directed to a publication containing a packaging bag. Referring to Fig. 8, in one embodiment of the invention a saddle stitched publication 60 comprises a plurality of sheets 61 having a top edge 62 and bottom edge 63 connected by spaced apart vertical side edges 64, 65. In the depicted embodiment of the invention tne sheets 61 are collated and folded to form a multi-page publication 60 having a central fold 66. Packaging bag 67 includes a plurality of sealed envelopes 68, 69 containing, one or more inserts (not shown). Envelopes 68, 69 are attached to each other along at least one margin of the envelopes, as described with respect to the packaging bag of the invention, above. At least two of the envelopes are separated by a fastening area 70, defined by vertical dashed lines 71(a) and 71(b). Packaging bag 67 is inserted between pages 72 and 73 (or, alternatively, on top of top sheet 74). The packaging bag need not be aligned so that the fastening area edges (such as 71(a),(b)) are parallel with the fold or so that the fold transects the fastening area, although this is preferred. However, bag 67 is inserted in publication 60 so that fastening area 70 of bag 67 overlaps central fold 66 and so that envelopes 68 and 69 are on opposite sides of fold 66.

[0079] The packaging bag may be secured between the pages of the publication e.g. by means of two staples inserted through the central fold. These staples may securely hold the bag in the publication by either a press fit across the fastening area by the stapled together publication pages, with one staple being above the packaging bag's upper edge 75 and the other staple being below the bag's lower edge depicted by horizontal dashed line 76. Alternatively or additionally, the packaging bag may be secured between the pages of the publication by means of at least one staple which extends through the fastening area 70 of the packaging bag and at least one sheet of the publication at the central fold 66, such as staples 77 in Fig. 8. The packaging bag may be bound at the head or foot of the publication or allowed to float during the binding process so that it is bound somewhere between the head or foot of the publication. If bound at either the head or foot a trim strip is required at the portion of the bag adjacent the head or foot, respectively, in order to allow for trimming of the head or foot edge of the publication without causing the packaging bag to be opened by such trimming operation.

[0080] The present invention is also directed to a process for making a packaging bag which is particularly adapted for incorporation into a publication which may be e.g. perfect bound, side stitched or folded in its final form and saddle stitched. Although tubular stock, such as seamless tubular film, may be employed in the process of the invention, it is preferred that sheet or "flat" sto be used. According to the preferred process, a continuous web of sheet or "flat" stock, such as may be provided by a roll of paper or some other material, is fed into an apparatus such as a "horizontal bagger" or horizontal packaging machine such that the sheet is progressively wrapped around a form or "forming block" so that two opposite edges of the sheet approximate or touch each other. When the stock is very long and relatively narrow, such as when the stock is fed to the process from a large roll of material, these edges will usually be the side or lengthwise ledges of the stock, as opposed to the endwise or widthwise edges.

[0081] The insert material to be included in one envelope is brought into proximity with the sheet, such as by conveyance by advancing pins to the under part of the forming block. As the sheet is folded around the form and the edges brought together the insert is enclosed within the sheet. Optionally, one or more edges may be coated with an adhesive. The edges of the sheet are fitted into a slot, which serves to hold both the edges together and the insert material in position within the sheet. One or more rollers, which preferably are heated, then contact the edges to apply pressure and preferably also heat. The edges are thereby sealed together such that the sheet forms an elongate tube with the insert material contained therein. This tube may be maintained in a cylindrical shape, but preferably is substantially collapsed so as to be relatively flat.

[0082] Regardless of whether tubular stock is used or a tube is formed by the preferred steps described above, the tube is then sealed at predetermined intervals along its length in a direction approximately perpendicular to the tube's longitudinal axis so as to form a plurality of compartments or envelopes which are separated from each other by at least one seal. In the embodiment which is preferred, two substantially parallel seals, separated by a relatively narrow, unsealed area, are made between each compartment or envelope.

[0083] Formation of the tube, incorporation of insert material, and sealing the tube to form compartments or envelopes may be accomplished using means known in the art, such as, for example, "horizontal baggers" or horizontal packaging machines. Specific machines for performing these steps are known in art (such as Fuji-Formost Wrappers) and are available from commercial sources.

[0084] The tube is cut widthwise periodically along its length to form a packaging bag. Although tubes wherein the compartments are separated by only one seal may be severed in the area of the seal so that one seal is cut to seal the ends of two separate envelopes, in the preferred embodiment wherein the envelopes are separated by two substantially parallel seals the cut preferably is made between the seals.

[0085] In one multi-envelope embodiment of the invention the cut will be made so that at least two envelopes are between successive cuts. Where more than two envelopes are between successive cuts, when the envelopes are of substantially equal size or envelopes of unequal size are made in pairs it is preferred that successive cuts be made between an even number of envelopes. It is further preferred that the number of envelopes between cuts be no more than two, with two envelopes being most preferred.

[0086] In one multi-envelope embodiment the packaging bag is folded about a fold line which may have perforations or a score or be formed by the folding operation itself such that at least one envelope lies on either side of the fold line. While the distance from the fold line to the opposing side edges of the packaging bag may be equal, optionally the distance may be unequal in order to provide a pick-up lip for use in collating. The packaging bags of the present invention may be supplied to a bindery in a folded condition, thereby removing the necessity for the bindery to fold the packaging bag prior to collation and binding.

[0087] Consistent with the invention, means for making the packaging bay's seals are known in the art. Suitable sealing means comprise fusion bonding, adhesive bonding, mechanical bonding or combinations thereof. For example, seals may be made by the application of pressure, heat or adhesive, or any combination thereof. The simultaneous application of both heat and pressure are preferred, particularly when the packaging bag is being made from a material which includes a plastic, such as laminates having a layer of polyethylene or polypropylene, wherein the plastic layer forms a heat sealing layer on the inside of the tube which may be fusion bonded by the application of heat and pressure. Crimping alone may be suitable for some materials such as paper to produce a mechanical bond. Also, adhesive may be used for paper, plastic and/or metallized materials. Suitable adhesives include such commonly employed adhesives as thermoplastic resin hot melt adhesives or modified polyvinylacetate or mixtures of petroleum wax with an EVA and a rosin-derived resin.

[0088] In the preferred multi-envelope embodiment wherein the envelopes are separated by two parallel seals and a packaging bag is formed which has two envelopes separated by two seals on either side of an approximately parallel row of perforations, widthwise sealing and severing of the tube preferably is accomplished by feeding the tube through the machine shown in an exploded form in Fig. 9. This machine is readily available from commercial sources, or may be made by modifying commercially available equipment using known techniques.

[0089] Referring to Fig. 9, the tube (not shown) is fed between rotating anvil roller 170 bearing anvil bars 172 (a),(b) and rotating cutting/perforating roller 174 bearing cutting blade 176 and perforating blade 178 bearing perforating teeth 180. The tube is sealed widthwise along its length by contacting the tube simultaneously with sealing surfaces 182 of sealer 183 attached to anvil roller 170 and the surface of corresponding sealing surfaces of sealer 184 attached to cutting/perforating roller 174. In the same step the tube is alternately cut by contacting the tube with cutting blade 176 and compressing the tube against anvil bar 172(b) and perforated by contacting the tube with perforating blade 178 and compressing the tube against anvil bar 172(a).

[0090] Referring now to Fig. 10, a schematic view is presented of a process of making a bag according to the present invention. A roll 80 of a packaging material dispenses in the direction indicated by arrows a web 81 having a first surface 82 and second opposing surface 83 with opposing side edges 84 and 85. A plurality of means for driving, supporting and/or changing the direction of movement of the web 81, such as rollers 86, 87, 88, 89a, 89b, 90 and 91, may be used to convey the web 81 to means for introducing an insert such a U-shaped rod 92. In Fig. 10, as web 81 unwinds downward from roll 80, it is moved in a horizontal direction by roller 86, and passes over roller 87 which. reverses its direction to roller 88. The web 81 travels downward from roller 88 and preferably travels over a triangular forming plate (not shown) to pinch rollers 89a, 89b, thereby causing web 81 to be folded, preferably in half, with surface 82 being folded against itself so that surface 83 forms the outer surface of the nov folded web having a folded edge 93 opposite side edges 84 and 85 which are positioned adjacent one another. Web 81 folds about the triangular folding plate at fold line 94a, 94b prior to traveling between pinch rollers 89a, 89b which complete the folding of the web 81, change its direction 90^o from the direction of travel off of roller 88 and drives the folded web. The web 81 is guided over rollers 90 and 91 which reverse the direction of the web 81. From roller 91 the web 81 travels over the U-shaped rod 92 which is positioned at a 45^o angle (alpha) to the direction of travel of the web approaching the rod 92. The folded edge 93 of web 81 travels around the curved portion 95 of the "U" of rod 92 causing the folded edge 93 to become inverted so that the outer surface 83 now becomes the inner surface 83. In other words, the folded web is inverted or turned inside out by the U-shaped rod 92 which simultaneously changes the direction of travel of the web 90^o from the direction of travel prior to contact with the rod 92. This inversion and change of direction permits introduction of an insert 96 such as printed cards or prepackaged product samples into the interior of the folded web. A plurality of inserts may be introduced to the moving folded web 81 e.g. by conveyance in a spaced apart relationship on a moving conveyor belt having pins or stops to urge the insert 96 into the interior of folded web 81. The folded web 81 is then sealed longitudinally e.g. by fusion bonding the surface 83 to itself adjacent side edges 84 and 85 by means of pressure and heat applied by sealing rollers 97a and 97b to form longitudinal seal 98. The seal 98 may be continuous or intermittent. Suitable seals will retain the insert 96 within the web and prevent exit of the insert through the longitudinal side edge. The longitudinal seal will be opposite the folded edge 93 a sufficient distance to provide an enclosed or tubular space which is sized to accept and surround the insert being packaged. The transverse width of the longitudinally sealed web 81 may be adjusted by cutting excess material from web 81 with rotating slitters 99a and 99b. The excess material 100 may be removed e.g. by a suction device 101. Also, an optional perforator may be provided e.g. by including perforating teeth 102 on slitter 99b. A series of perforations 103 may be made by teeth 102, thereby providing an easy means to open the sealed web to remove the enclosed insert. The web 81 then travels through transverse sealer/perforator means such as opposing rotary sealers 104a and 104b. Top sealer 104a rotates in a counter-clockwise direction as indicated by arrows A in synchronicity with opposing bottom sealer 104b which rotates in a clockwise direction. Web 81 travels between the two sealers 104a, 104b which are positioned so that the sealing heads 105 and 106 of respective sealers 104a and 104b contact the web 81 at suitable intervals to provide transverse seals 107 forming with folded edge 93 and longitudinal seal 98 a plurality of envelopes 108a, 108b. The transverse seals 107 may be intermittent as long as they are capable of preventing loss of the enclosed insert 96 therethrough, but preferably each of the seals 107 will be a continuous closure extending from the folded edge 93 to longitudinal seal 98. The sealers may be provided with a cutting knife, perforating knife and/or scoring rule to provide perforations, a score line and/or cut the web transversely. For example, in the embodiment depicted in Fig. 10, sealing head 105 if bifurcated by perforating knife 109 which produces transverse perforations 110 in transverse seal 107 which separates opposing envelopes 108a and 108b. Sealing head 106 is bifurcated by cutting knife 111 which periodically severes web 81 transversely to provide a plurality of packaging bags 112 having two envelopes 108a, 108b. It should be apparent that the cutting means may be modified to provide packaging bags having one, two, or three or more envelopes containing inserts 96. Furthermore, a plurality of inserts 96 may be continuously provided so that adjacent inserts are the same or different and a series of inserts of 2, 3, 4 or more may be provided according to a scheme designed to provide one or more packaging bags having predetermined inserts so that the bags produced may be supplied to a bindery for subsequent incorporation into a publication in such a manner that different inserts will be provided in each envelope contained in a single individual copy of a publication, yet it will be possible to provide each copy of a plurality of copies of a particular publication with the same series of inserts for each copy.

[0091] It should be apparent that rotary sealers 104a, 104b could in another embodiment, e.g. for producing packaging bags containing a single envelope, be replaced by a combination guillotine sealer/cutter. Also, perforating, scoring, sealing and cutting operations may be provided by separate devices or devices having various combinations of functions and features.

[0092] Referring again to Fig. 10, the formed, severed packaging bag 112 exiting the cutting means may be conveyed by a transfer means, such as a conveyor belt 113, for boxing in a flattened condition or to a folding area where the bags 112 are manually or by automatic equipment folded. Folding may be facilitated by provision of a fold line 114 which may be formed e.g. by perforations 110 or by an indentation made by scoring.

[0093] Referring now to Fig. 11, a front view is shown of a packaging bag 120 according to one embodiment of the invention. Packaging bag 120 is formed from a web or sheet of material which is folded to overlap a front wall portion 121 with a back wall portion. Opposite and parallel to folded edge 122 is top edge 123. The folded edge 122 and top edge 123 are connected by opposing parallel spinal edge 124 and side edge 125. The spinal edge 124 and side edge 125 extend perpendicular to both the top edge 123 and the folded edge 122. A longitudinal seal 126 extends perpendicular to transverse seals 127a and 127b, which intersect the longitudinal seal 126. The front wall portion 121 and overlapped back wall portion are sealed together circumferentially about an insert 128 to form a sealed envelope 129. The depicted embodiment shows the folded edge 122 as the bottom edge of the envelope 129 and packaging bag 120, but the folded edge may be the top edge, spinal edge or side edge as well.

[0094] In one embodiment a rectangular sheet is folded in half and sealed together to provide an envelope with front and back wall portions meeting at the fold. Opposite the fold a distal edge of the front wall portion is in substantial alignment with a distal edge of the back wall portion with both of these edges extending parallel to the fold. In another embodiment the sealed folded sheet is as described above, but the distal edge (distal from the fold) of the front wall portion is parallel to the back wall edge (distal from the fold) but the edges are offset instead of coextensive. The embodiment with coextensive edges may provide a bag having a strong double thickness edge suitable for jogging into position. The embodiment with offset edges while of less strength may produce less waste in a trimming operation.

[0095] Referring again to Fig. 11, the packaging bag 120 is provided with a trim segment 130 along its top edge 123. A second trim segment 131 extends along the spinal edge 124 and is perpendicular to trim segment 130. Trim segments may also be provided on any or all sides of the bag 120 including the bottom edge 122 and side edge 125. The trim segments function as an edge which may be roughly aligned with collated pages in a publication and subsequently subjected to a cutting or trimming operation to remove a portion of the trim segment along with trimming the pages edges e.g. to produce a plurality of publications having a predetermined uniform size with even edges. Trim segments will generally have a width of at least 1/8 inch with some embodiments having a width of at least 1/4 inch and others having a width of at least 1/2 inch. Typically the trim segment width will range between about 1/16 inch to about 1 inch and preferably between about 1/8 inch to about 1/4 inch. Different trim segments on the same packaging bag may have different widths. The width of each trim segment is typically measured from the bag's outer edge to an envelope detachment line such as a series of perforations or to a sealing area which defines an outer boundary of the envelope. For example for the top trim segment 130, the width is measured from top edge 123 to longitudinal seal 126. The purpose of the trim segment is to allow a publication having a packaging bag bound therein to be trimmed without damaging or cutting open the sealed envelope. Therefore in all embodiments of the invention the trim segment may include a portion of the seal as long as the seal is not totally removed or its integrity damaged to an extent thereby the contents of the envelope may fall out. In one embodiment the sealing area is coextensive with the trim segment. A trim segment which comprises a sealed together front wall portion and back wall portion may have added strength to support the bag without unintended folding during collation and any jogging or shaking operation to position the bag.

[0096] Packaging bag 120 has a series of perforations 132 extending from the top edge 123 to the opposing bottom 122 whereby the sealed envelope 129 is separable from the fastening area 133 by tearing along the perforations 132. Thus, bag 120 may be bound into a publication by bag binding means at fastening area 133 and the sealed envelope may be separated from the publication by tearing along the perforations 132.

[0097] The fastening area 133 is utilized to fasten the bag 120 to a publication in the publication's spinal area. Fastening area 133 extends along the spinal edge 124 and is coextensive with the spinal trim segment. The width of the spinal trim segment is measured from the spinal edge toward the transverse seal 127a. In this embodiment, the trim segment should not extend past perforations 132. Preferably, the spinal trim segment (which extends along the spinal edge) will have a width of at least about 1/8 inch. Bag 120 also has printed thereon indicia 134 on a front wall panel 135 circumscribed by seal 126, seal 127a, bottom edge 122 and perforations 132.

[0098] In another embodiment of the invention a sealing area such as seal 127a may be coextensive with the fastening area and/or a spinal trim segment.

[0099] In all embodiments of the invention the width of the seals may vary but preferably the seals will have a width between about 1/8 inch to about 1 inch. Seals having widths smaller than 1/8 inch may not have sufficient strength to maintain the insert in the envelope during normal handling. Whether or not a seal has sufficient strength will of course depend upon not only the seal width, but the type of seals, whether they are continuous or intermittent and the type, shape, and eight of the insert, as well as parameters relating to publication formation and handling. Such variables will be taken into account in forming seals and satisfactory seals of sufficient width may be determined without undue experimentation. Seals widths larger than 1 inch (2.5 cm) may be employed but generally are not necessary.

[0100] Referring again to Fig. 11, the envelope 129 has perforations 136 across the front wall portion 121 and back wall portion (not shown) from top edge 123 to bottom edge 122 whereby the envelope 129 is openable by tearing along the perforations 136. Such perforations may extend only along a portion of the envelope 129 as long as they facilitate formation of an opening sufficient to remove the insert.

[0101] Envelope 129 and bag 120 may be colored, black, white, printed, opaque, translucent, and transparent. In Fig. 11 bag 120 is printed upon with indicia 134, but is otherwise transparent allowing visual perception of the insert 128 contained in a sealed envelope 129. Insert 128 is a prepackaged product sample of e.g. scented suntan lotion which contains its own information and indicia 137 imprinted thereon. Advantageously, an odor barrier film may be used to prepackage the product sample as an insert 128 for subsequent packaging in bag 120 which may be made of an inexpensive material such as paper or polypropylene without concern for odor release, leakage, oxygen or moisture or gas or liquid permeability. Insert 128 may be product samples which are preferably prepackaged or printed matter e.g. a plurality of printed cards.

[0102] Referring now to Fig. 12, a front view of a publication 140 is depicted with a cut away portion showing a packaging bag 120 having a sealed envelope 129 contained therein. The packaging bag 120 of Fig. 11 is especially suited for binding into a perfect bound or side-stitched publication. Publication 140 has a top page 141 which has a top edge 142, spinal edge 143, bottom edge 144, and side edge 145. Top page 141 is printed with indicia 146. Page 141 is collated with a plurality of pages such as middle page 147 having printed indicia 148. Bag 120 is collated within publication 140 atop page 147 with the top edge 123 of bag 120 in envelope 129 having top trim segment 130 in substantial alignment with the publication's pages such as the top edge 142 of page 141. The spinal trim segment 131 of bag 120 is adjacent to the spinal edge of the publication's pages such as top page spinal edge 143. The collated pages and bag will normally be subjected to a trimming operation prior to binding.

[0103] Referring now to Fig. 13, a top view is presented of the collated bag 120 and pages of publication 140 of Fig. 12. Dimensions are exaggerated for clarity of illustration. Top page 141, bottom page 149 and middle pages such as middle page 147 have a collective spinal edge 150 and side edge 151 which are uneven.

[0104] Referring now to Fig. 14, a top view is presented of the collated publication 140 of Fig. 13 following a trimming and binding operation. Side edge 151 and spinal edge 150 have been trimmed and are even. A layer of a flexible adhesive 152 has been applied to spinal edge 150 as binding means for binding together a plurality of pages and packaging bag 120. A cover sheet 153 has also been attached to the spine at the outer surface of the flexible adhesive 152 to produce a finished publication.

[0105] A variety of materials may be used to form the packaging bag, consistent with the invention, and many suitable materials are available from commercial sources. Either tubular or sheet stock may be employed, having monolayer or multilayer contruction. Stock selected from the group consisting of paper, cellophane, and thermoplastic films including those made from homopolymers and copolymers of olefins, such as polyethylene and polypropylene, linear low density polyethylene and very low density polyethylene, may be suitably employed as well as films made from polyesters and biodegradable plastics. The stock may be single layer or multilayer stock formed by well known lamination processes or coextrusion means. The stock may be coated with various agents to improve printability, sealability, or to control static electricity or other parameters. The stock may also be metallized. Many such films are commercially available and well known in the art. Examples of preferred stock include paper, polyethylene, polypropylene and a laminate of metallized polyester and polyethylene.

[0106] Further modification of the packaging bag, process and publication of the invention described herein will be apparent to those of ordinary skill in the art, and all such modifications and changes are deemed within the scope of the invention as defined by the following claims.

Claims

1. A publication comprising:
a plurality of pages, wherein said pages have parallel opposing top and bottom edges connected by a spinal portion which extends perpendicular to said top and bottom edges and said pages are bound together at said spinal portion by binding means; and
a packaging bag bound to said spinal portion, said bag comprising at least one sealed envelope containing at least one insert therein, and wherein said envelope comprises overlaying front and back wall portions, each of said wall portions having opposing top and bottom edges connected by opposing spinal and side edges, at least one of said top and bottom edges having a trim segment, and said spinal edge having an adjacent or coextensive fastening area whereby said bag is bound to said spinal portion of said plurality of bound pages.

2. A publication, as defined in Claim 1, wherein said pages are saddle stitch bound.

3. A publication, as defined in Claim 1, wherein said pages are side stitch bound.

4. A publication, as defined in Claim 1, wherein said pages are perfect bound.

5. A publication, as defined in Claim 1, wherein said binding means comprises at least one staple.

6. A publication, as defined in Claim 1, wherein said binding means comprises an adhesive.

7. A publication, as defined in Claim 1, wherein said spinal portion is formed from folding at least one sheet to form a plurality of pages and said spinal portion extends along at least one portion of said fold.

8. A publication, as defined in Claim 1, wherein said insert comprises a prepackaged product sample.

9. A publication, as defined in Claim 1, wherein said insert comprises printed matter.

10. A publication, as defined in Claim 1, wherein said insert comprises a product sample of seeds, cosmetics, fabrics, paint chips, food, a personal hygiene product, an agricultural chemical, or a cleaning supply.

11. A publication, as defined in Claim 1, wherein said bag is bound to said spinal portion of said pages by said binding means for said pages.

12. A publication, as defined in Claim 1, wherein said bag is bound to said spiral portion of said pages by bag binding means which is in addition to said page binding means.

13. A publication, as defined by Claim 12, wherein said bag binding means comprises at least one staple or an adhesive in contact with said bag or en trapping said bag within said pages.

14. A publication, as defined in Claim 1, wherein said envelope comprises one or more layers of a metal foil, a thermoplastic film, a cellulosic material, or a combination thereof.

15. A publication, as defined in Claim 1, wherein each of said front and back wall portions of said sealed envelope is formed from separate sheets which are sealed together circumferentially about said insert to form said sealed envelope.

16. A publication, as defined in Claim 1, wherein said front and back wall portions of said sealed envelope are formed from a folded web or sheet which has overlapping portions which are sealed together circumferentially about an insert to form said sealed envelope.

17. A publication, as defined in Claim 16, wherein said folded web or sheet has its fold forming said top edge of said envelope.

18. A publication, as defined in Claim 16, wherein said folded web or sheet has its fold forming said bottom edge of said envelope.

19. A publication, as defined in Claim 16, wherein said folded sheet has a fold forming said side edge of said envelope.

20. A publication, as defined in Claim 16, wherein said folded sheet is rectangular and said front and back wall portions of said folded sheet meet at the fold and opposite said fold have a distal edge of said front wall portion in substantial alignment with a distal edge of said back wall portion, said front and back wall edges extending parallel to said fold.

21. A publication, as defined in Claim 16, wherein said folded sheet is rectangular, said front and back wall portions meet at a fold of said folded sheet and each of said front and back wall portions has a distal edge which is parallel to and away from said fold, and said distal edge of said front wall portion is parallel to but offset from said distal edge of said back wall portion.

22. A publication, as defined in Claim 1, wherein said trim segment has a width of at least 1/8 inch.

23. A publication, as defined in Claim 1, wherein said trim segment has a width of at least 1/4 inch.

24. A publication, as defined in Claim 1, wherein said trim segment has a width of between about 1/16 inch to about 1 inch.

25. A publication, as defined in Claim 1, wherein said trim segment has a width of between about 1/8 inch to about 1/4 inch.

26. A publication, as defined in claim 1, wherein said insert comprises a plurality of printed cards.

27. A publication, as defined in Claim 1, wherein said spinal edge of said envelope further comprises a spinal edge trim segment which extends along said spinal edge opposite said fastening area from said insert, and has a trim segment width of at least 1/8 inch.

28. A publication, as defined in Claim 1, wherein said packaging bag is bound to said spinal portion with said top edge of said envelope in substantial alignment with said top edge of said pages and wherein said top edge of said envelope has a trim segment extending along said top edge.

29. A publication, as defined in Claim 1, wherein said packaging bag is bound to said spinal portion with said bottom edge of said envelope in substantial alignment with said bottom edge of said pages and wherein said bottom edge of said envelope comprises a trim segment extending along said bottom edge.

30. A publication, as defined in Claim 1, wherein said front and back wall portions are connected by sealing means in at least one sealing area located circumferentially about said insert whereby said sealing means and said sealing area are sufficient to retain said insert within said envelope.

31. A publication, as defined in Claim 30, wherein said sealing means comprise fusion bonding, adhesive bonding, mechanical bonding or a combination thereof.

32. A publication, as defined in Claim 30, wherein said sealing area forms, with said front and back wall portions, a continuously sealed envelope.

33. A publication, as defined in Claim 30, wherein said sealing area comprises a pair of parallel spaced-apart elongate seals connected by a elongate seal which is perpendicular thereto.

34. A publication, as defined in Claim 33, wherein said seals have a width between about 1/8 inch to about 1 inch.

35. A publication, as defined in Claim 30, wherein at least a portion of said sealing area is coextensive with said trim segment.

36. A publication, as defined in Claim 30, wherein at least a portion of said sealing area is coextensive with said fastening area.

37. A publication, as defined in Claim 36, further comprising a spinal edge trim segment which extends along said spinal edge and has a spinal edge trim segment width of at least about 1/8 inch.

38. A publication, as defined in Claim 37, wherein said spinal edge trim segment is coextensive with said sealing area.

39. A publication, as defined in Claim 30, wherein said envelope is perforated across a portion of at least one wall of said envelope whereby said envelope is openable by tearing along said perforations.

40. A publication, as defined in Claim 30, wherein said packaging bag has a series of perforations extending from one edge of said bag to an opposing edge whereby said envelope is separable from said publication by tearing along said perforations.

41. A publication, as defined in Claim 1, wherein said at least one sealed envelope comprises a least two sealed envelopes connected by said spinal edge, said edge being common to and coextensive with said at least two envelopes.

42. A publication, as defined in Claim 41, wherein said spinal edge is coextensive with said fastening area, said fastening area being common to said at least two envelopes.

43. A publication, as defined in Claim 41, wherein said at least two envelopes have respective opposing fastening areas connected by and adjacent to said spinal edge.

44. A publication, as defined in Claim 41, wherein said spinal edge is scored for folding.

45. A publication, as defined in Claim 41, wherein the distance from the common and coextensive spinal edge to the side edge of at least one of said envelopes is greater than the distance from said spinal edge to a side edge of a second of said envelopes.

46. A publication, as defined in Claim 45, wherein said distances are different by at least about 1/4 inch.

47. A publication, as defined in Claim 46, wherein said distances are different by at least about 3/8 inch.

48. A publication containing a packaging bag comprising (a) a plurality of pages folded and collated to form a multi-page publication having a central fold, and (b) a packaging bag which includes a plurality of sealed envelopes containing one or more inserts and being attached to each other along at least one margin of said envelopes, at least two of said envelopes being separated by a fastening area, said packaging bag being inserted between pages of said publication such that said fastening area overlaps said central fold and at least two of said envelopes are on opposite sides of said fold.

49. The publication of Claim 48 wherein said packaging bag is secured between the pages of said publication by means of at least one staple which is stapled through said fastening area and said central fold.

50. A package comprising a sealed envelope containing at least one insert, said envelope having a front wall and a back wall, and at least two sides having a trim segment, said trim segment of at least one of said sides extending perpendicular to the other, each of said trim segments having sufficient width for removal by a magazine trimming operation without opening said envelope, said width being at least about 1/16 inch.

51. A package, as defined in claim 50, wherein said width of said trim segments is at least about 1/8 inch.

52. A package, as defined in claim 50, wherein said width of said trim segments is between about 1/8 inch to about 3/4 inch.

53. A package, as defined in claim 50, wherein said insert comprises a prepackaged product sample or printed matter.

54. A package comprising a thin walled bag having a top edge and opposing bottom edge connected by opposing first and second side edges, said bag having a fastening area with a fold or fold line therein and extending from said top edge to said bottom edge, wherein said bag further comprises on each side of said fastening area at least one sealed envelope containing at least one insert, and the distance from said fold or fold line to said first side edge of said bag is different from the distance from said fold or fold line to said second side edge of said bag.

55. A package, as defined in Claim 54, wherein said difference in distance between said fold or fold line and said opposing first and second side edges is at least about 1/4 inch.

56. A package, as defined in Claim 54, wherein said difference in distance between said fold or fold line and said opposing first and second side edges is at least about 3/8 inch.

57. A package, as defined in Claim 54, wherein said difference in distance between said fold or fold line and said opposing first and second side edges is at least about 1/2 inch.

58. A package, as defined in Claim 54, wherein said bag is folded.

59. A package, as defined in Claim 54, wherein said bag has a fold line formed by a score.

60. A package, as defined in Claim 54, wherein said bag has a fold line formed by a series of perforations.

61. A package, as defined in Claim 54, wherein at least one of said top, bottom and side edges of said bag further comprises a trim segment.

62. A process for making a packaging bag adapted for insertion into a publication, said process comprising: longitudinally folding a web of paper, foil or thermoplastic film;
inserting an insert comprising a prepackaged product sample or a plurality of printed cards into the interior of said folded web; and
sealing said web circumferentially about said insert, thereby forming a sealed rectangular envelope having a longitudinal seal opposite a folded edge, said folded edge and longitudinal seal being connected by spaced apart opposing transverse seals.

63. A process for making a publication containing a packaging bag, said process comprising:
collating a plurality of pages with a packaging bag, as defined in claim 50;
binding said pages and said bag together along a spinal edge; and
trimming at least one of said bag and said pages.

64. A process for making a publication containing a packaging bag, said process comprising:
collating a plurality of pages with a packaging bag, as defined in claim 54;
binding said pages and said bag together along a spinal edge; and
trimming at least one edge of said bag and said pages.

Drawing